Method of manufacturing organic electroluminescence display device and electronic equipment including organic electroluminescence display device manufactured by the manufacturing method

ABSTRACT

Provided is a method of manufacturing an organic electroluminescence display device including an organic electroluminescence element, which has element characteristics comparable to those in the case of a vacuum in-situ process, while utilizing a patterning approach based on photolithography. The method of manufacturing an organic electroluminescence display device includes: an organic compound layer-forming step of forming an organic compound layer at least on a first electrode; a release layer-forming step of forming a release layer on the organic compound layer; a release layer-processing step of processing the release layer; and an organic compound layer-processing step of removing the organic compound layer in a region not covered with the release layer processed in the release layer-processing step, and at least the lowermost layer out of the release layer is a deposited film formed of a material soluble in a polar solvent.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of manufacturing an organic electroluminescence (EL) display device and an electronic equipment including an organic EL display device manufactured by the manufacturing method.

2. Description of the Related Art

A generally known display device having organic EL elements mounted thereon is a device in which pixels each having a single or multiple organic EL elements are arranged in a predetermined pattern. By those pixels, a display region of the display device is two-dimensionally and finely divided. The organic EL elements included in the pixels are electronic elements which output, for example, any one of red light, green light, and blue light. A display device having organic EL elements mounted thereon obtains a full-color image by driving the organic EL elements for outputting desired colors at desired emission intensities.

By the way, in an organic EL element which is a component of a display device, an organic compound layer in the element is a thin film layer formed by forming a thin film made of an organic material by vapor deposition or the like. When the organic compound layer in the organic EL element of the display device is formed for each element by vapor deposition, a fine patterning technology is necessary. Upon performance of the patterning, a fine metal mask the fineness of which is according to the fineness of the patterning is necessary. However, a vapor deposited film which adheres when the metal mask is used repeatedly in vapor deposition may narrow an opening in the mask or stress may deform the opening in the mask. Therefore, it is necessary to clean the mask used after film formation for a fixed number of times, which is a disadvantageous factor from the viewpoint of manufacturing costs. Further, partly due to a limitation on the process accuracy of the mask, the pixel size has a limit of about 100 μm, which is disadvantageous to a finer size. Further, with regard to the substrate size, when a fine metal mask is increased in size, in order to secure the positional accuracy of the opening in the mask, it is necessary to enhance the stiffness of a frame of the mask. However, when the stiffness of the mask is enhanced, an increase in the weight of the mask itself is caused accordingly. Therefore, from the viewpoint of both processability and handling, when large format display devices of the fourth and subsequent generations are to be produced, an optimum production process of a fine organic EL element and a display device having the organic EL element mounted thereon has not taken shape at present.

Under those circumstances, a method of producing a display device having a fine organic EL element without using a metal mask is proposed.

In the method proposed in Japanese Patent No. 3839276, a photoresist is directly formed on an emission layer. When the method is adopted, the photoresist to be used generally contains large amounts of a photoinitiator, a crosslinking agent, and the like. Here, the photoinitiator, the crosslinking agent, and the like are each a material for changing insolubility at least in a developer. In the method proposed in Japanese Patent No. 4507759, an intermediate layer formed of a water-soluble material is provided on an organic compound layer, and the organic compound layer is patterned by performing photolithography on the intermediate layer. Here, a water-soluble polymer for constituting the intermediate layer to be formed on an emission layer is generally insulative. In addition, Japanese Patent No. 4544811 proposes such a technology that a water-soluble polymer is used as a release layer and a photoresist is released together with the release layer.

The resist, the intermediate layer, the release layer, and the like are generally insulative. Accordingly, when any one of those layers is being left on the surface of the emission layer or the like of an organic EL element, the layer serves as a resistance to remarkably deteriorate the element characteristics of the organic EL element. Accordingly, the resist, the intermediate layer, the release layer, and the like need to be removed so that none of the layers may remain on the surface of the emission layer or the like. However, it is difficult to completely remove the resist, the intermediate layer, the release layer, and the like each formed of a polymer material, and hence the residue that cannot be completely removed remains in the device to some extent. Further, concern is raised about the deterioration of the element characteristics due to, for example, the following. A trace amount of an impurity in the resist, the intermediate layer, the release layer, or the like, or a solvent to be used upon application of the resist, the intermediate layer, the release layer, or the like diffuses to the emission layer or the like constituting the organic compound layer to cause the crystallization of the organic compound layer. Accordingly, the following problem has conventionally arisen. The element characteristics of an organic EL element in an organic EL display device produced by patterning involving utilizing a photolithography process are inferior to the element characteristics of organic EL elements formed like a pattern with a metal mask or the like in a vacuum in-situ fashion.

SUMMARY OF THE INVENTION

The present invention has been made to solve the problems, and an object of the present invention is to provide a method of manufacturing an organic EL display device including an organic EL element, which has element characteristics comparable to those of an organic EL element formed with a metal mask or the like in a vacuum in-situ fashion, while utilizing a patterning approach based on photolithography.

The method of manufacturing an organic EL display device of the present invention is a method of manufacturing an organic EL display device having an organic EL element including a first electrode and a second electrode, and an organic compound layer arranged between the first electrode and the second electrode, the organic compound layer being patterned into a desired shape, the method including: an organic compound layer-forming step of forming the organic compound layer at least on the first electrode; a release layer-forming step of forming a release layer on the organic compound layer; a release layer-processing step of processing the release layer into the desired shape; an organic compound layer-processing step of removing the organic compound layer in a region not covered with the release layer processed in the release layer-processing step; and a release layer-removing step, in which at least a lowermost layer of the release layer is a deposited film formed of a material soluble in a polar solvent.

According to the present invention, there can be provided a method of manufacturing an organic EL display device including an organic EL element, which has element characteristics comparable to those of an organic EL element formed with a metal mask or the like in a vacuum in-situ fashion, while utilizing a patterning approach based on photolithography.

Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic sectional view illustrating an example of an organic EL display device to be manufactured by a manufacturing method of the present invention.

FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H, 2I, 2J, 2K, 2L, 2M, 2N, and 2O are each a schematic sectional view illustrating Embodiment 1 in the method of manufacturing an organic EL display device of the present invention.

FIG. 3 is a graph illustrating thickness changes in a compound 1 and a compound A2 over an etching time.

FIG. 4 is a graph illustrating the solubilities of a predetermined aromatic hydrocarbon compound and a predetermined heterocyclic compound in an aqueous solution of isopropyl alcohol.

FIGS. 5A, 5B, 5C, 5D, and 5E are each a schematic sectional view illustrating Embodiment 2 in the method of manufacturing an organic EL display device of the present invention.

FIGS. 6A, 6B, 6C, 6D, 6E, and 6F are each a schematic sectional view illustrating Embodiment 3 in the method of manufacturing an organic EL display device of the present invention.

FIG. 7 is a block diagram of a digital camera system using an organic EL display device formed by the method of manufacturing an organic EL display device of the present invention.

DESCRIPTION OF THE EMBODIMENTS

A method of manufacturing an organic EL display device of the present invention is a method of manufacturing an organic EL display device having an organic EL element including a first electrode and a second electrode, and an organic compound layer arranged between the first electrode and the second electrode, the organic compound layer being patterned into a desired shape.

The manufacturing method of the present invention includes at least the following steps (A) to (E):

(A) an organic compound layer-forming step of forming the organic compound layer on the first electrode;

(B) a release layer-forming step of forming a release layer on the organic compound layer;

(C) a release layer-processing step of processing the release layer into a desired shape;

(D) an organic compound layer-processing step of removing the organic compound layer in a region not covered with the release layer processed in the release layer-processing step; and

(E) the step of removing the release layer with a polar solvent.

In addition, in the present invention, at least the lowermost layer of the release layer is a deposited film soluble in the polar solvent. Further, as a preferred mode in the present invention, the step of forming a layer containing an alkali metal component on the organic compound layer is further included after the step (E).

Hereinafter, an embodiment of the present invention is described with reference to drawings. It should be noted that in the following description, a well-known technology or known technology in the technical field is applicable to a portion not specifically illustrated or described. In addition, embodiments to be described below are each merely one embodiment of the present invention, and the present invention is not limited thereto. In addition, the embodiments to be described below may be appropriately combined as long as the combination does not deviate from the gist of the present invention.

Embodiment 1 Organic EL Display Device

FIG. 1 is a schematic sectional view illustrating an example of an organic EL display device to be manufactured by the manufacturing method of the present invention. An organic EL display device 1 of FIG. 1 has three kinds of sub-pixels, that is, a first sub-pixel 20 a, a second sub-pixel 20 b, and a third sub-pixel 20 c provided on a supporting substrate 10. Here, a pixel is constituted of the first sub-pixel 20 a, the second sub-pixel 20 b, and the third sub-pixel 20 c. Although one pixel formed of the first sub-pixel 20 a, the second sub-pixel 20 b, and the third sub-pixel 20 c is illustrated in the organic EL display device 1 of FIG. 1, multiple pixels are placed in a matrix fashion on the supporting substrate 10 in an actual organic EL display device.

In addition, in the organic EL display device 1 of FIG. 1, each sub-pixel (20 a, 20 b, or 20 c) has a first electrode 21 (21 a, 21 b, 21 c), an organic compound layer 22 (22 a, 22 b, 22 c), a charge injection/transport layer 23, and a second electrode 24.

The first electrode 21 a, 21 b, or 21 c is electrode layer (lower electrode) provided on the supporting substrate 10, and is separately provided for each sub-pixel. In addition, the first electrodes 21 a, 21 b, and 21 c are each electrically connected to a switching element (not shown) such as a TFT.

The organic compound layer 22 a, 22 b, or 22 c is single layer formed of a predetermined organic compound or a laminate formed of multiple layers of such kind. It should be noted that the organic compound layer 22 a, 22 b, or 22 c has at least an emission layer (not shown) for outputting light of any one of the colors including a red color, a green color, and a blue color.

The charge injection/transport layer 23 is provided for injecting or transporting a hole or electron injected from the second electrode 24 into the organic compound layer 22. Although the charge injection/transport layer 23 is provided as a layer common to the respective sub-pixels (20 a, 20 b, and 20 c) in the organic EL display device 1 of FIG. 1, the present invention is not limited thereto. In other words, the charge injection/transport layer 23 may be separately provided for each sub-pixel.

Although the second electrode 24 (upper electrode) is provided as a layer common to the respective sub-pixels (20 a, 20 b, and 20 c) as in the charge injection/transport layer 23 in the organic EL display device 1 of FIG. 1, the present invention is not limited thereto. In other words, the second electrode 24 may be separately provided for each sub-pixel.

(Method of Manufacturing Organic EL Display Device)

Next, a method of manufacturing an organic EL display device including three kinds of sub-pixels for displaying colors different from one another is described as a specific example of the method of manufacturing an organic EL display device of FIG. 1 according to the present invention.

As described above, the method of manufacturing an organic EL display device of the present invention includes at least the following steps (A) to (E):

(A) an organic compound layer-forming step of forming an organic compound layer on a first electrode;

(B) a release layer-forming step of forming a release layer on the organic compound layer;

(C) a release layer-processing step of processing the release layer into a desired shape;

(D) an organic compound layer-processing step of removing the organic compound layer in a region not covered with the release layer processed in the release layer-processing step for the release layer; and

(E) a step of removing the release layer with a polar solvent.

FIGS. 2A to 2O are each a schematic sectional view illustrating an example of a manufacturing process for the organic EL display device of FIG. 1. FIGS. 2A to 2O are each also a schematic sectional view illustrating Embodiment 1 in the method of manufacturing an organic EL display device of the present invention. Upon manufacture of the organic EL display device of FIG. 1, the organic EL display device is manufactured by, for example, the following steps:

(1) the step of forming the first electrode (FIG. 2A);

(2) the step of forming the organic compound layer (FIG. 2B);

(3) the step of forming the release layer (FIG. 2C);

(4) the step of forming a photosensitive resin layer (FIG. 2D);

(5) the step of processing the photosensitive resin layer (FIG. 2E);

(6) the step of processing the release layer (FIG. 2F);

(7) the step of processing the organic compound layer (FIG. 2G);

(8) the step of removing the photosensitive resin layer (FIG. 2L);

(9) the step of removing the release layer (step of forming the charge transport layer) (FIG. 2M);

(10) the step of forming the charge injection/transport layer (FIG. 2N); and

(11) the step of forming the second electrode (FIG. 2O).

It should be noted that the steps (1) to (11) are merely specific examples, and the present invention is not limited to the mode. As the organic EL display device 1 of FIG. 1 requires the production of each of the three kinds of sub-pixels 20 a, 20 b, and 20 c having different luminescent colors, the steps (2) to (7) need to be performed a total of three times after the performance of the step (1) before the performance of the step (8). For example, first, the organic compound layer 22 a in the first sub-pixel 20 a is formed by the steps (2) to (7) (FIG. 2G). Then, the organic compound layer 22 b in the second sub-pixel 20 b is formed by the steps (2) to (7) (FIG. 2H to FIG. 2I). After that, the organic compound layer 22 c in the third sub-pixel 20 c is formed by the steps (2) to (7) (FIG. 2J to FIG. 2K).

Next, each of the steps (1) to (11) is specifically described.

(Step of Forming First Electrode)

First, the first electrodes 21 a, 21 b, and 21 c are formed on the supporting substrate 10. A known substrate such as a glass substrate can be selected as the supporting substrate 10. The first electrodes 21 a, 21 b, and 21 c are electrode layers each formed of a known electrode material, and the constituent material is appropriately selected in correspondence with a light extraction direction. When a top emission type organic EL display device is produced, the first electrodes 21 a, 21 b, and 21 c are reflecting electrodes, and the second electrode 24 to be described later is a light transmissive electrode. On the other hand, when a bottom emission type organic EL display device is produced, the first electrodes 21 a, 21 b, and 21 c are light transmissive electrodes, and the second electrode 24 is a reflecting electrode.

When the first electrodes 21 a, 21 b, and 21 c are formed as reflecting electrodes, the constituent material for each of the first electrodes 21 a, 21 b, and 21 c is preferably a metal material such as Cr, Al, Ag, Au, or Pt. Of those metal materials, a material having a high reflectance is more preferred because the material can additionally improve light extraction efficiency. A reflecting electrode is separately formed for each sub-pixel by, for example, forming a thin film of the metal material by a known method such as sputtering and processing the thin film into a desired shape by means of photolithography or the like. It should be noted that a layer formed of an oxide semiconductor having light-transmitting property such as ITO or IZO may be further provided on the thin film formed of any such metal material by reason of, for example, the protection of the thin film or the regulation of a work function. Vapor deposition with a metal mask may also be utilized upon formation of the first electrodes 21 a, 21 b, and 21 c. Even when the vapor deposition with a metal mask is performed, the first electrode 21 a, 21 b, or 21 c is separately formed for each sub-pixel.

When the first electrodes 21 a, 21 b, and 21 c are formed as light transmissive electrodes, examples of the constituent material for each of the first electrodes 21 a, 21 b, and 21 c include oxide semiconductors having light-transmitting properties such as indium tin oxide (ITO) and indium zinc oxide.

(Step of Forming Organic Compound Layer)

The organic compound layer 22 (22 a, 22 b, or 22 c) is a constituent member for the organic EL display device, and is a single layer, or a laminate formed of multiple layers, including at least an emission layer. A layer except the emission layer in the organic compound layer 22 is, for example, a hole injection layer, a hole transport layer, an electron blocking layer, a hole blocking layer, an electron transport layer, or an electron injection layer, provided that the present invention is not limited thereto. Here, a layer contacting the emission layer may be a charge transport layer (a hole transport layer or an electron transport layer), or may be a charge blocking layer (an electron blocking layer or a hole blocking layer).

In addition, a specific constitution of the organic compound layer 22 with respect to the first electrode 21 has only to be appropriately set in accordance with the kind of carrier to be injected from the first electrode 21 toward the organic compound layer 22. That is, when a hole is injected from the first electrode 21, while a layer for injecting or transporting a hole (a hole injection layer or a hole transport layer) is provided on the side of the first electrode 21, a layer for injecting or transporting an electron (an electron injection layer or an electron transport layer) is provided on the side of the second electrode 24. On the other hand, when an electron is injected from the first electrode 21, while a layer for injecting or transporting an electron (an electron injection layer or an electron transport layer) is provided on the side of the first electrode 21, a layer for injecting or transporting a hole (a hole injection layer or a hole transport layer) is provided on the side of the second electrode 24.

It should be noted that the organic compound layer 22 is preferably an amorphous film from the viewpoint of luminous efficiency. In addition, the thickness of each organic layer is preferably designed depending on a luminous wavelength in a proper fashion so that an optical interference effect may be obtained.

When one, or each of both, of a hole injection layer and a hole transport layer is provided, a hole-injectable/transportable material as a constituent material for the hole injection layer or the hole transport layer is not particularly limited, but a material having a work function at least smaller than that of a constituent material for the emission layer and having high hole-transporting property is preferably used. In addition, the hole injection layer or the hole transport layer may be provided with a function of blocking an electron flowing from the emission layer as well as a function of transporting a hole. Alternatively, separately from the hole injection layer or the hole transport layer, a layer having a function of blocking an electron flowing from the emission layer (electron blocking layer) may be inserted between the hole transport layer (or the hole injection layer) and the emission layer.

For example, an arylamine derivative, a stilbene derivative, a polyarylene, a condensed polycyclic hydrocarbon compound, a heterocyclic aromatic compound, a heterocyclic condensed polycyclic compound, and an organometallic complex compound, and homooligomers and heterooligomers thereof can each be used as an organic luminescence material of each color (red color/green color/blue color) in the emission layer, provided that the luminescence material in the present invention is not limited to the materials.

It should be noted that the luminescent colors of the emission layers in the three kinds of organic compound layers 22 a, 22 b, and 22 c provided for the lower electrodes 21 a, 21 b, and 21 c, respectively upon manufacture of the organic EL display device of FIG. 1 are a blue color, a red color, and a green color, respectively, i.e., the luminescent colors are different from one another. In addition, a combination of the luminescent colors is not particularly limited.

A constituent material for the hole blocking layer is not particularly limited as long as the material has an energy barrier for preventing the leak of a hole from the emission layer toward a cathode and has electron-transporting property.

In the present invention, the uppermost layer of the organic compound layer 22 to be formed in the step of forming the organic compound layer is preferably a layer formed of a material having a lower solubility in the polar solvent than the release layer (especially the lowermost layer of the release layer) does. Here, the uppermost layer of the organic compound layer 22 is an emission layer, a hole blocking layer, an electron blocking layer, a charge transport layer (a hole transport layer or an electron transport layer), or a charge injection layer (an electron injection layer or a hole injection layer). In addition, the material having a low solubility in a polar solvent is specifically a condensed polycyclic hydrocarbon compound except a compound having an m-terphenyl group.

Here, the condensed polycyclic hydrocarbon compound is a cyclic, unsaturated organic compound constituted only of a hydrocarbon. More specifically, the compound is a compound containing a condensed ring obtained by the condensation of at least one side of an aromatic ring such as a benzene ring. Specific examples of the condensed polycyclic hydrocarbon compound include naphthalene, fluorene, fluoranthene, chrysene, anthracene, tetracene, phenanthrene, pyrene, and triphenylene.

However, it is hard to utilize the condensed polycyclic hydrocarbon compound as a constituent material for the organic compound layer because the compound has low heat stability when used as it is. Therefore, a compound obtained by adding a substituent to such condensed polycyclic hydrocarbon compound is used as a constituent material for the organic compound layer.

Here, a compound as a constituent material for, in particular, the uppermost layer of the organic compound layer is preferably an organic compound obtained by the bonding of the multiple condensed polycyclic hydrocarbon compounds except a compound having an m-terphenyl group with a single bond. The organic compound includes a compound obtained by appropriately substituting the condensed polycyclic hydrocarbon compound as a main skeleton with an alkyl group such as a methyl group or an ethyl group. It should be noted that such organic compound does not include any compound having a heteroatom (such as N or O) in its main chain or a substituent thereof.

A layer formed of the condensed polycyclic hydrocarbon compounds has charge-transporting property.

It should be noted that an existing method such as a vacuum deposition method, a spin coating method, a dip coating method, or an ink jet method can be employed as a method of forming the layer formed of the aromatic hydrocarbon compound. The film forming-method is more preferably the vacuum deposition method in consideration of the emission characteristic of the organic EL display device.

(Step of Forming Release Layer)

A release layer 30 to be provided on the organic compound layer 22 may be a single layer, or may be a laminate formed of multiple layers. In the present invention, when the release layer 30 is formed of a single layer, the layer is a deposited film formed of a material soluble in a polar solvent. Alternatively, when the release layer 30 is a laminate formed of multiple layers, at least the lowermost layer out of the layers constituting the laminate is a layer formed of a low-molecular weight material formed into a film by the vacuum deposition method. More specifically, the lowermost layer of the release layer 30 is a deposited film formed of the material soluble in the polar solvent. When the uppermost layer of the organic compound layer is formed of a material having a low solubility in the polar solvent, the lowermost layer of the release layer on the layer is formed of a deposited film formed of a material soluble in the polar solvent, and the polar solvent is used upon removal of the release layer, the release layer 30 can be selectively removed. The term “polar solvent” as used herein refers to a liquid formed of one kind of polar solvent or a mixed liquid of multiple kinds of polar solvents, and does not comprehend a mixed liquid of a polar solvent and a non-polar solvent (such as toluene or benzene). This is because when a liquid for removing the release layer contains a non-polar solvent, there is a high possibility that the liquid dissolves the organic compound layer. In addition, the release layer 30 in the present invention is preferably an amorphous film.

Here, the reason why the release layer 30 (or at least the lowermost layer thereof) is a deposited film formed by the vacuum deposition method is described. The deposited film formed by the vacuum deposition method is a film that has solidified after passing a gas state at least once. Here, the damage received by the organic compound layer 22 upon contact of a material in the gas state with the surface of the organic compound layer 22 is relatively small. Accordingly, it can be said that the film formation by the vacuum deposition method is a film-forming method that does small damage to the organic compound layer 22. In addition, a material to be formed into a film by the vacuum deposition method is naturally limited to a low-molecular weight compound capable of vaporization in a vacuum state because the vacuum deposition method is a thin film-forming method applied to a compound having high sublimation property. In addition, the molecular weight of the compound in the deposited film is small as compared with that of a polymer material, and hence an interaction (intermolecular force) between molecules constituting the deposited film is weak and their adsorption forces to the organic compound layer 22 are also weak. Further, the states of the molecules in the deposited film formed in an amorphous state such as the orientations of the molecules with respect to each other are random. As a result, an intermolecular distance becomes large as compared with those in a solid state and a crystalline state, and hence a state where the molecules are spread out and a solvent molecule is easy to enter, that is, a state where the molecules are easily dissolved is established. Accordingly, when the deposited film (of the organic compound) formed by the vacuum deposition method is used as the release layer 30, the release layer 30 can be easily removed by being brought into contact with the polar solvent.

Specific examples of the polar solvent include water, an organic compound having a heteroatom (such as N, O, or S), and a mixed solvent obtained by mixing water and an organic compound having a heteroatom (such as N, O, or S).

Here, a molecule in a solvent or mixed solvent listed as the polar solvent necessarily contains a heteroatom, and the heteroatom functions as a polar site of the molecule in the polar solvent. Then, the polar site interacts with a polar site in a constituent material for the release layer, and hence the constituent material for the release layer is dissolved in the polar solvent. In addition, the interaction between the polar sites affects the solubilities of various compounds in the polar solvent. In consideration of the foregoing, the solubility of the lowermost layer of the release layer in the polar solvent can be improved as compared with the solubility of the uppermost layer of the organic compound layer therein by appropriately selecting the polar solvent while taking into consideration the structure of the compound to be used as the constituent material for the release layer 30.

A compound that dissolves in the polar solvent is, for example, a compound having a polar site (heteroatom) or a compound having an m-terphenyl group. The compound is more specifically a heterocyclic compound, or an organic compound having an electron-donating or electron-withdrawing substituent.

(1) Heterocyclic Compound

In the present invention, a heterocyclic compound may be used as the constituent material for the release layer 30. The term “heterocyclic compound” as used herein refers to, for example, a group of compounds each containing, as a basic skeleton, a heterocyclic compound such as pyridine, bipyridine, triazine, phenanthroline, quinoline, imidazole, oxazole, thiazole, oxadiazole, and thiadiazole. It should be noted that when such compound contains quinoline as a basic skeleton, the compound may be a quinolinate complex. Compounds included in the compound group of heterocyclic compounds are, for example, the following compounds.

(2) Group of Compounds Each Having m-Terphenyl Group

In the present invention, a compound having an m-terphenyl group may be used as the constituent material for the release layer 30. In addition, the release layer 30 is preferably formed by co-depositing the compound having an m-terphenyl group and the heterocyclic compound from the vapor from the viewpoint of its heat stability such as a glass transition temperature. Examples of the compound having an m-terphenyl group include the following compounds.

(3) Group of Compounds Each Having Electron-Withdrawing Group

In the present invention, a compound having an electron-withdrawing group may be used as the constituent material for the release layer 30. Examples of the compound having an electron-withdrawing group include the following compounds.

(4) Group of Compounds Each Having Organic Acid Site or Organic Acid Derivative Site

In the present invention, a compound having, as a substituent, an organic acid or a derivative of the organic acid such as an ester may be used as the constituent material for the release layer 30. Examples of the compound having an organic acid site or an organic acid derivative site include the following compounds.

Of the four kinds of compound groups, one kind may be used alone, or two or more kinds thereof may be appropriately used in combination from the viewpoint of an improvement in solubility in the polar solvent.

In a heterocyclic compound, charge is localized on a heteroelement except carbon (such as N, O, or S). In the case of, for example, pyridine having a nitrogen atom in its ring, the polarity of an entire molecule is caused by the localization of negative charge on the nitrogen atom. Here, when a polar solvent containing a hydrogen atom of a hydroxyl group (—OH) or the like on which positive charge is localized interposes, a hydrogen bond is formed between the site (N atom) which the heterocyclic compound has and on which negative charge is localized, and the hydrogen atom in a polar solvent molecule on which positive charge is localized. When the hydrogen bond is formed as described above, the heterocyclic compound dissolves, or becomes easily soluble, in the polar solvent.

Similarly, a compound whose polarity is caused by the fact that the compound contains at least a heteroatom (such as N, O, or S) has improved solubility in the polar solvent as compared with that of a condensed polycyclic hydrocarbon compound.

For example, the bias of n-electrons occurs in a compound obtained by introducing an electron-withdrawing group or an electron-donating group into an aromatic ring, thereby causing polarization. Here, when an electron-withdrawing substituent is introduced, negative charge is localized on the substituent to cause polarity. When an electron-donating substituent is introduced, positive charge is localized on the substituent to cause polarity. The occurrence of the polarity enables an interaction with a solvent molecule of the polar solvent, thereby improving the solubility in the polar solvent. The solubility in the polar solvent can also be improved when the molecular structure contains an organic acid or an organic acid derivative (such as an ester).

A substituent whose polarity is caused by the fact that the substituent contains a heteroatom as described above is, for example, a hydroxyl group, a thiol group, an enol, a carbonic acid ester, a sulfuric acid ester, a boronic acid ester, or a phosphoric acid ester. When a compound has any such substituent, an acid-base reaction, a hydrogen bond, an interaction between polar sites, hydration, or the like in accordance with the acidity of a proton portion occurs, and hence the compound dissolves in the polar solvent. When an aromatic ring is substituted with such functional group as described above, the functional group serves as an electron-withdrawing group as well.

On the other hand, the size of a molecule itself of an aromatic hydrocarbon compound free of any condensed ring, specifically, such a compound that benzene rings are linked to each other with a single bond is small as compared with that of a condensed polycyclic hydrocarbon compound. As a result, the former compound has improved solubility in the polar solvent as compared with that of the condensed polycyclic hydrocarbon compound. Molecules each having an m-terphenyl structure are of structures particularly hard to crystallize because the molecules are of such structures as to hardly orient with respect to each other. As a result, the solubility in the polar solvent is additionally improved.

In contrast, the condensed polycyclic hydrocarbon compound has extremely poor solubility in the polar solvent because of the following reasons. The compound shows extremely small bias of n-electrons on its rings, has no site capable of interacting with a solvent molecule of the polar solvent, and is large as one unit (basic skeleton). Therefore, the use of such material in the uppermost layer of the organic compound layer enables the protection of any other organic compound layer from the polar solvent for removing the release layer.

Here, a difference between the solubilities of the constituent material for the organic compound layer and the constituent material for the release layer in the polar solvent is described. Description is given by taking, as specific examples, the etching rates of: the following compound 1 as a compound having a condensed polycyclic hydrocarbon to be used as the constituent material for the organic compound layer; and the following compound A2 to be used as the constituent material for the release layer.

In the present invention, a larger etching rate means a higher dissolution rate. In addition, a larger etching rate means a higher solubility of a layer having a material of interest in the solvent (polar solvent).

FIG. 3 is a graph illustrating thickness changes in the compound 1 and the compound A2 over an etching time. Here, FIG. 3 illustrates the results of the etching of the respective layers when a mixed solvent obtained by mixing isopropyl alcohol (IPA) and water so that IPA may account for 60 wt % (hereinafter, sometimes referred to as “IPA/water mixed solvent”) is used as a polar solvent.

As can be seen from FIG. 3, a layer (layer A) formed of the compound 1 as a condensed polycyclic hydrocarbon compound shows nearly no thickness reduction even when the etching time is lengthened. On the other hand, the thickness of a layer (layer B) formed of the compound A2 as a heterocyclic compound reduces over time. When the etching rates of the respective layers are calculated with their etching conditions made identical to each other, the etching rate of the layer A is 0.008 nm/sec but the etching rate of the layer B is 0.87 nm/sec, that is, a ratio of the latter to the former is about 100.

Here, a ratio (n) between the etching rates of the uppermost layer (layer A) of the organic compound layer and the lowermost layer (layer B) of the release layer by the polar solvent used upon removal of the release layer under the same temperature conditions can be represented like the following equation.

$n = \frac{\left\lbrack {{Etching}\mspace{14mu}{rate}\mspace{14mu}{of}\mspace{14mu}{lowermost}\mspace{14mu}{layer}\mspace{14mu}{of}\mspace{14mu}{release}\mspace{14mu}{layer}} \right\rbrack}{\left\lbrack {{Etching}\mspace{14mu}{rate}\mspace{14mu}{of}\mspace{14mu}{uppermost}\mspace{14mu}{layer}\mspace{14mu}{of}\mspace{14mu}{organic}\mspace{14mu}{compound}\mspace{14mu}{layer}} \right\rbrack}$

In the present invention, n needs to be at least larger than 1. n is preferably larger than 10 (n>10). Here, when the compound 1 is used in the uppermost layer of the organic compound layer and the compound A2 is used in the lowermost layer of the release layer, n becomes about 100. Accordingly, when the constituent material for the uppermost layer of the organic compound layer and the constituent material for the lowermost layer of the release layer are selected in consideration of the solubility of each material in the polar solvent, an etching rate ratio (ratio of the solubilities) between both layers can be increased. As a result, selective removal of the release layer with the polar solvent is enabled.

The solubility of a compound as a constituent material for each layer in the IPA/water mixed solvent varies depending on the weight ratio of IPA in the mixed solvent. FIG. 4 is a graph illustrating the solubilities of the compound 1 (condensed polycyclic hydrocarbon compound) and the compound A2 (heterocyclic compound) in the IPA/water mixed solvent (polar solvent). Here, in the graph of FIG. 4, the axis of abscissa indicates the weight percent concentration of IPA in the IPA/water mixed solvent, and the axis of ordinate indicates the amount of the condensed polycyclic hydrocarbon compound or heterocyclic compound to dissolve in 1 g of the solvent. As can be seen from FIG. 4, while the amount in which the compound 1 (condensed polycyclic hydrocarbon compound) dissolves in 1 g of the IPA/water mixed solvent having an IPA concentration of 80 wt % is 5 μg, the dissolution amount of the compound A2 (heterocyclic compound) is 73 μg.

FIG. 4 is also a graph that proves the following items (a) and (b):

(a) when the concentration of IPA in the IPA/water mixed solvent is excessively high, both the constituent material for the release layer and the constituent material for the organic compound layer dissolve in the IPA/water mixed solvent at so high rates that a situation in which the etching rate ratio (n) is close to 1 is established; and (b) in the case of the item (a), adding water to reduce the concentration of IPA can enlarge the etching rate ratio (n) while reducing the dissolution rates of the respective materials.

As described above, the constituent material for the release layer 30 is selected in consideration of factors that dominate the solubility in the polar solvent such as an interaction between polar sites, a hydrogen bond, and a molecular size. Such selection can increase the solubility of the release layer 30 in the polar solvent as compared with the solubility of any layer constituting the adjacent organic compound layer therein, provided that a polar solvent except water involves the following possibility. The difference in solubility does not become so large depending on the kind and concentration of the solvent, and hence the etching rate ratio approaches 1.

In such case, the solvent is preferably used as a polar solvent mixed with water. Specifically, the water content is preferably regulated in an appropriate fashion so that the etching rate of the release layer may be even larger than that of the organic compound layer. The water content is more preferably regulated in an appropriate fashion so that the etching rate ratio (n) of the release layer to the layer positioned at the uppermost layer in the organic compound layer may exceed 10. As a result, a more selective removal of the release layer is enabled and hence reductions in the characteristics of the organic EL display device can be prevented.

(Step of Processing Release Layer)

In the present invention, a photolithography method can be suitably utilized as means for patterning (processing) the release layer 30 into a desired shape. Here, a processing process for the release layer involving utilizing the photolithography method is described.

(i) Steps of Forming and Processing Photosensitive Resin Layer

When the photolithography method is utilized, a photosensitive resin layer 40 needs to be provided on the release layer 30 first. A known material can be used as a photosensitive resin as a constituent material for the photosensitive resin layer 40. In addition, an existing method such as a spin coating method, a dip coating method, or an ink jet method can be employed as a method of forming the photosensitive resin layer 40. A vacuum deposition method can be utilized in some situations.

After the formation of the photosensitive resin layer 40, the photosensitive resin layer 40 is processed. Here, the step of processing the photosensitive resin layer 40 is divided into the exposure of the photosensitive resin layer (exposing step) and the development of the photosensitive resin layer (developing step).

Here, an existing photoirradiation apparatus can be used in the exposing step. It should be noted that an exposure apparatus in accordance with the fineness of a pattern has only to be used. In addition, upon performance of the exposing step, a photomask 50 having an opening is used in a region to be exposed. It should be noted that a general photomask having, on a light transmissive base substrate, a light-shielding region formed of a Cr thin film in accordance with a pattern to be formed can be used as the photomask. Meanwhile, ultraviolet light or visible light can be utilized as light with which the photosensitive resin layer 40 is irradiated in the exposing step.

By the way, upon performance of the exposing step, the exposure region of the photosensitive resin layer 40 is desirably determined in consideration of the nature of the photosensitive resin as the constituent material for the photosensitive resin layer 40. Specifically, when a positive photosensitive resin is used, a region from which one wishes to remove the photosensitive resin layer 40 in the next developing step is defined as the exposure region. On the other hand, when a negative photosensitive resin is used, a region where he or she wishes to leave the photosensitive resin layer 40 when the next developing step is performed is defined as the exposure region. Here, FIG. 2E illustrates the case where a positive photosensitive resin is used. In FIG. 2E, a region 42 out of the photosensitive resin layer 40 irradiated with ultraviolet light 51 is removed in the next developing step. Meanwhile, a region 41 shielded from the ultraviolet light with the photomask 50 serves to protect the organic compound layer 22 a provided for a predetermined region (the first sub-pixel 20) in the step of processing the release layer or the step of processing the organic compound layer to be performed later.

Upon performance of the developing step, a developer suitable for the photosensitive resin as the constituent material for the photosensitive resin layer 40 has only to be used.

(ii) Step of Processing Release Layer

Next, the release layer 30 is processed by selectively removing a region out of the release layer 30 not covered with the photosensitive resin layer 40. Although a method of selectively removing the release layer 30 is not particularly limited, specifically, an existing thin film-processing method such as wet etching or dry etching can be employed, provided that the dry etching in which an influence of side etching by a solvent is smaller than that of any other method is preferred because a reduction in pattern accuracy can be suppressed.

In the foregoing description, a photolithography process involving using a photoresist is utilized as means for processing the release layer 30, but a method of processing the release layer 30 is not limited thereto. For example, the release layer may be patterned into a desired shape by utilizing an ink jet mode, printing, laser processing, or the like. In this case, the release layer patterned into the desired shape can be formed without the formation of any photoresist. Accordingly, it is recommended that the release layer 30 be utilized as an etching mask upon processing of the organic compound layer in the next step (step of processing the organic compound layer). It should be noted that upon utilization of the release layer 30 as an etching mask, the thickness of the release layer 30 is preferably at least larger than that of the organic compound layer.

(Step of Processing Organic Compound Layer)

Next, the organic compound layer 22 in a region out of the organic compound layer 22 not covered with the release layer 30 is selectively removed. A method of processing the organic compound layer 22 is not particularly limited, and an existing method such as wet etching or dry etching can be employed, provided that the dry etching is preferred because no concern is raised about side etching by a solvent.

Through the foregoing process, the organic compound layer can be formed so as to be selectively provided only for a predetermined sub-pixel. In addition, the organic compound layer desired only for each sub-pixel can be selectively formed in the sub-pixel by repeatedly performing the steps ranging from the step of forming the organic compound layer to the step of processing the organic compound layer described above a number of times corresponding to the number of kinds of sub-pixels.

(Step of Removing Photosensitive Resin Layer)

In the manufacturing method of the present invention, after the processing of the organic compound layer 22 has been performed, the release layer 30 and the photosensitive resin layer 41 laminated on the organic compound layer 22 are each removed.

When the photosensitive resin layer 40 is removed, an existing method such as wet etching or dry etching can be employed. In the present invention, the dry etching that raises no concern about side etching by a solvent is preferred because a reduction in pattern accuracy can be suppressed.

(Step of Removing Release Layer)

The release layer 30 is removed with the polar solvent. The release layer 30 is particularly preferably removed after the patterning of the organic compound layers 22 a, 22 b, and 22 c has been completed and after a layer above the release layer has been removed. This is because reductions in element characteristics due to the inclusion of an impurity in, for example, a layer such as a photoresist to be formed above the release layer, or a developer or release liquid for the photoresist into the organic compound layer during the process can be avoided. In addition, the solvent is more preferably a solvent containing water. It should be noted that one kind of polar solvent may be incorporated into the solvent, or a mixture of multiple kinds of polar solvents may be incorporated into the solvent.

Here, the term “polar solvent” refers to an organic solvent having polarity. Examples thereof include alcohols, polyhydric alcohols, ketones, esters, pyridines, and ethers, provided that a solvent having a boiling point at least lower than the decomposition temperature or glass transition temperature of the organic compound in the organic compound layer 22 is preferably selected because the solvent needs to be removed by being volatilized in the step to be described later. In the cases of, for example, the alcohols, methanol, ethanol, isopropyl alcohol, or the like can be suitably used.

The removal of the release layer 30 exposes the uppermost layer of the organic compound layer 22. At this time, the etching rate of the uppermost layer of the organic compound layer 22 is slow as compared with that of the release layer 30 because the constituent material for the uppermost layer of the organic compound layer 22 is a condensed polycyclic hydrocarbon compound. As a result, in the step of removing the release layer, the uppermost layer of the organic compound layer 22 is substantially free of being dissolved, and hence the release layer 30 can be selectively removed while an end portion of the organic compound layer 22 is substantially prevented from damaging. In addition, in the step, the uppermost layer of the organic compound layer is substantially free of being dissolved, and hence the organic compound layer remains nearly intact. Accordingly, its thickness can be managed in an additionally strict fashion. The thickness is of particular importance upon control of a luminescent color by means of a cavity effect. Accordingly, the ability to manage the thickness in an additionally strict fashion leads to the reduction of a characteristic variation in a display device or between display devices, thereby enabling an increase in yield.

After the removal of the release layer 30, the solvent remaining on the supporting substrate 10 provided with the organic compound layer 22 or on the organic compound layer 22 is preferably removed by heating the supporting substrate 10. The supporting substrate 10 is more preferably heated under a vacuum condition at about 80° C. When the solvent is removed by heating the supporting substrate 10 as described above, a charge injection layer or a charge transport layer can be formed in the next step in a state where the formation is not affected by the solvent. It should be noted that the supporting substrate 10 may be heated in a vacuum before the performance of the next step. The vacuum heating can also reduce an influence such as the adhesion of water, oxygen, or foreign matter in the atmosphere.

(Step of Forming Charge Injection/Transport Layer)

After the removal of the release layer 30, the charge injection/transport layer 23 is formed on the organic compound layer 22. It should be noted that the charge injection/transport layer 23 is preferably formed as a layer common to the respective sub-pixels. In addition, the manufacturing method of the present invention is a method suitable upon formation of a layer containing an alkali metal component or an alkaline-earth metal component as a charge injection layer.

When an electron injection layer is formed as the charge injection/transport layer 23, an electron injection material as a constituent material for the electron injection layer desirably has a high work function. Examples of such material include an alkali metal, an alkaline-earth metal, a material obtained by doping an electron transport material with an alkali metal, an alkali metal compound (oxide, carbonate, or halogenated salt), and an alkaline-earth metal compound (oxide, carbonate, or halogenated salt). Here, cesium, potassium, and lithium can be given as specific examples of the alkali metal. In addition, specific examples of the alkaline-earth metal include calcium and barium.

On the other hand, when a hole injection layer is formed as the charge injection/transport layer 23, an organic compound having a small work function and an electron-withdrawing material having an extremely deep work function can be suitably given as examples of a hole injection material as a constituent material for the hole injection layer. An arylamine compound and phthalocyanine can be given as examples of the organic compound having a small work function. In addition, F4-TCNQ, an azatriphenylene compound (such as PPDN or hexacyano-hexaazatriphenylene), molybdenum oxide, and tungsten oxide can be given as examples of the electron-withdrawing material having a deep work function.

(Step of Forming Second Electrode)

When a top emission type organic EL display device is produced, the second electrode 24 corresponding to the upper electrode is a transparent electrode formed of a transparent conductive material. The transparent conductive material having light-transmitting property is preferably a material having a high light transmittance. Examples of such material include: transparent conductive materials such as ITO, indium zinc oxide, and ZnO; and organic conductive materials such as a polyacetylene. It should be noted that a semitransmissive film obtained by forming a metal material such as Ag or Al into a film having a thickness of about 10 nm to 30 nm may be used as the second electrode 24. Here, when a light transmissive electrode is formed of a transparent conductive material such as ITO, indium zinc oxide, or ZnO, composition that satisfies both a low resistance characteristic required for the composition to be used in an electrode and a high transmittance characteristic needed for an improvement in light extraction efficiency is preferred for a reduction in power consumption. A thin film to serve as the light transmissive electrode can be formed by a known method such as sputtering. When a transparent conductive film that brings together the low resistance characteristic and the high transmittance characteristic is produced, the volume of a film-forming apparatus, a target, the pressure in the apparatus, and an output voltage at the time of the film formation need to be appropriately adjusted. It should be noted that the second electrode 24 is electrically connected to a switching element such as a transistor (not shown). As described above, the manufacturing method of the present invention is a manufacturing method without using a fine metal mask. Therefore, the manufacture of an organic EL display device having as fine a pixel size as about 10 μm and a large supporting substrate size in its fifth generation and afterward can be realized.

(Driving Method of Organic EL Display Device)

The organic EL display device manufactured by the manufacturing method of the present invention can be driven by applying a voltage between the first electrode 21 and the second electrode 24 which each sub-pixel (20 a, 20 b, or 20 c) has. Here, when the voltage is applied, for example, power source means (not shown) electrically connected to each electrode through a transistor is used.

Embodiment 2

FIGS. 5A to 5E are each a schematic sectional view illustrating Embodiment 2 in the method of manufacturing an organic EL display device of the present invention. Here, Embodiment 2 differs from Embodiment 1 in that a protective layer 60 is formed on the release layer 30 after the step of forming the release layer 30 (FIG. 5A). Hereinafter, Embodiment 2 is described with particular emphasis on its difference from Embodiment 1.

(Step of Forming Protective Layer)

In the manufacturing method of the present invention, as illustrated in FIG. 5A, the protective layer 60 may be formed on the release layer 30 after the step of forming the release layer 30. Here, the protective layer 60 to be formed on the release layer 30 is a film insoluble in water and an organic solvent, and is preferably a film having moisture resistance and gas barrier property. Here, the protective layer 60 more preferably has such characteristic as to absorb light to be applied at the time of photolithography. The protective layer 60 to be formed in the manufacturing method of the present invention is preferably a thin-film layer of an inorganic compound using silicon nitride (SiN) as a main material.

By the way, the formation of the protective layer 60 on the release layer 30 eliminates the possibility that the solvent to be used upon formation of the photosensitive resin layer 40 in the next step permeates the release layer 30 to contact the organic compound layer 22. Accordingly, upon selection of the solvent of the photosensitive resin layer 40, such a restraint that the solvent should not dissolve the organic compound layer 22 is lifted, and hence an additionally cheap material can also be selected.

(Step of Processing Protective Layer)

When the protective layer 60 is provided between the photosensitive resin layer 40 and the release layer 30, the processing of the protective layer 60 needs to be performed before the processing of the release layer 30 is performed. Here, the processing of the protective layer 60 is specifically selective removal of a region out of the protective layer 60 not covered with a photosensitive resin layer 41 (photosensitive resin not exposed in the exposing step) (FIG. 5B). Although a method of selectively removing the protective layer 60 is not particularly limited, a known technology such as wet etching or dry etching can be utilized. For example, when a constituent material for the protective layer 60 is SiN, dry etching involving using CF₄ as a reactant gas can be utilized.

(Step of Removing Protective Layer Etc.)

After the step of processing the protective layer described above has been performed, the processing of the release layer 30 and the organic compound layer 22 a is performed in the same manner as in Embodiment 1 (FIG. 5C). It should be noted that the photosensitive resin layer 41 may be removed simultaneously upon performance of the processing of the organic compound layer 22 a.

After that, the steps ranging from the formation of the organic compound layer (22 b or 22 c) to the processing of the organic compound layer are performed in each sub-pixel (FIG. 5D), and then the protective layer 60 and the release layer 30 are removed (FIG. 5E). When the protective layer 60 is provided between the release layer and the photosensitive resin layer 40 like this embodiment, the protective layer 60 is removed by a method (such as dry etching or wet etching) utilized during the step of processing the protective layer after the removal of the photosensitive resin layer 40. After that, the release layer 30 is removed with the polar solvent. Alternatively, the protective layer 60 may be removed together with the release layer 30 by selectively removing the release layer 30 with the polar solvent in a state where the protective layer 60 is not removed.

Embodiment 3

FIGS. 6A to 6F are each a schematic sectional view illustrating Embodiment 3 in the method of manufacturing an organic EL display device of the present invention. Here, Embodiment 3 differs from Embodiment 2 in that a protective layer 60 is formed of multiple layers (a first protective layer 61 and a second protective layer 62) (FIG. 6A). Hereinafter, Embodiment 3 is described with particular emphasis on its difference from Embodiment 2.

(Step of Forming Protective Layer)

As illustrated in FIG. 5A and FIG. 6A, the protective layer 60 may be a single layer, or may be multiple layers. When the protective layer is a laminate formed of two layers, a first protective layer 61 to be formed first is preferably formed of a water-soluble material. In addition, a second protective layer 62 to be formed subsequently to the first protective layer 61 is preferably a film of an inorganic compound using, as a main material, a material insoluble in water and an organic solvent such as silicon nitride.

Examples of the water-soluble material as a constituent material for the first protective layer 61 include known water-soluble polymer materials such as a polyvinyl alcohol, a polyethylene glycol, and a polyvinyl pyrrolidone. In addition, an existing method such as a known spin coating method, dip coating method, or ink jet method can be employed upon formation of the first protective layer. Here, the organic compound layer 22 is not etched by a solvent upon formation of the first protective layer 61 because the organic compound layer 22 is a layer formed of a material that does not dissolve in water. In addition, when the protective layer 60 is formed so as to have a large thickness, an influence such as the dissolution of the organic compound layer 22 by the solvent of the photosensitive resin layer 40, a reduction in the thickness of the organic compound layer 22, or the elution of a luminescence material can be additionally alleviated.

(Step of Processing Protective Layer)

In addition, when the protective layer 60 is constituted of multiple layers, each protective layer needs to be processed. For example, when the protective layer 60 is a laminate obtained by laminating the first protective layer 61 formed of a water-soluble polymer and the second protective layer 62 formed of SiN in the stated order from the substrate 10 side, each protective layer is processed by the following method. First, the second protective layer as an upper layer is subjected to dry etching involving using CF₄ as a reactant gas (FIG. 6B), and then the first protective layer as a lower layer is subjected to dry etching involving using CF₄ as a reactant gas (FIG. 6C).

(Step of Removing Protective Layer Etc.)

After the step of processing the protective layer described above has been performed, the processing of the release layer 30 and the organic compound layer 22 a is performed in the same manner as in Embodiment 2 (FIG. 6D). It should be noted that, as illustrated in FIG. 6D, the removal of the photosensitive resin layer 41 may be simultaneously performed upon performance of the processing of the organic compound layer 22 a.

After that, the steps ranging from the formation of the organic compound layer (22 b or 22 c) to the processing of the organic compound layer are performed in each sub-pixel (FIG. 6E), and then the protective layer 60 and the release layer are removed (FIG. 6F). When the protective layer 60 is provided between the release layer and the photosensitive resin layer 40 like this embodiment, the protective layer 60 is removed by a method (such as dry etching or wet etching) utilized during the step of processing the protective layer after the removal of the photosensitive resin layer 40. After that, the release layer 30 is removed with the polar solvent. Alternatively, the following may be adopted. While the photosensitive resin layer 40 is not removed, the first protective layer 61 is selectively dissolved by being brought into contact with water so that the second protective layer 62 and the photosensitive resin layer 40 formed on the first protective layer 61 may be removed together. After that, the release layer 30 is removed with the polar solvent. Alternatively, the following may be adopted. While the photosensitive resin layer 40 and the protective layer 60 are not removed, the release layer 30 is removed with the polar solvent so that the layers may be removed together with the release layer.

Next, the present invention is described by way of examples. However, the present invention is not limited to the examples to be described below. For example, the order in which sub-pixels are formed in terms of their luminescent colors is not limited to the order “blue, green, and red.” For example, the constitution and thickness of the organic compound layer are also not limited to the information described in the examples. For example, when an electron is injected from the first electrode, the order in which the layers of the organic compound layer are laminated in accordance with the injection has only to be adopted. A combination of the examples to be described below is also included in the present invention. A well-known or known technology in the technical field is applied to a portion not specifically illustrated or described in the specification.

Example 1

The organic EL display device illustrated in FIG. 1 was produced in accordance with the process illustrated in FIGS. 2A to 2O.

(1) Step of Forming First Electrode

First, by a sputtering method, an aluminum alloy (AlNd) was formed into a film on a supporting substrate 10 so that an AlNd film (reflecting electrode) was formed. At this time, the thickness of the AlNd film was set to 100 nm. Then, by a sputtering method, ITO was formed into a film on the AlNd film so that an ITO film was formed. At this time, the thickness of the ITO film was set to 10 nm. It should be noted that a laminate formed of the AlNd film and the ITO film functioned as the first electrode 21. Next, the first electrodes 21 a, 21 b, and 21 c constituting the first sub-pixel, the second sub-pixel, and the third sub-pixel, respectively were each produced by performing the patterning of the first electrode 21 based on a photolithography process (FIG. 2A).

(2) Step of Forming Blue Organic Compound Layer

The blue organic compound layer 22 a was formed on the supporting substrate 10 on which the patterned first electrodes (21 a, 21 b, and 21 c) had been formed by continuous film formation involving employing a vacuum deposition method. First, a hole transport layer was formed so as to have a thickness of 120 nm, and then an emission layer containing a blue luminescence material was formed so as to have a thickness of 30 nm. Next, a condensed polycyclic hydrocarbon compound represented by the following formula [1] was formed into a film so that a hole blocking layer was formed. At this time, the thickness of the hole blocking layer was set to 10 nm. Thus, the organic compound layer 22 a (blue organic compound layer) was formed (FIG. 2B).

(3) Step of Forming Release Layer

Next, a phenanthroline derivative represented by the following formula [2] was formed into a film by a vacuum deposition method so that the release layer 30 was formed. At this time, the thickness of the release layer 30 was set to 500 nm (FIG. 2C).

(4) Steps of Forming and Processing Photosensitive Resin Layer

Next, a positive photoresist (available under the product name “AZ1500” from AZ Electronic Materials) was formed into a film by a spin coating method so that the photosensitive resin layer 40 was formed (FIG. 2D). At this time, the thickness of the photosensitive resin layer was 1,000 nm. Next, exposure to the ultraviolet light 51 was performed with an exposure apparatus (Mask Aligner MPA600 manufactured by Canon Inc.) in a state where the photosensitive resin layer 41 provided for the region of the first sub-pixel 20 a was shielded with the photomask 50 so that the photosensitive resin layer 41 was left (FIG. 2E). At this time, an exposure time was 40 s. After the exposure, development was performed with a developer (prepared by diluting a product available under the product name “312MIF” from AZ Electronic Materials with water so that its concentration was 50%) for 1 minute. A photosensitive resin layer 42 exposed to the ultraviolet light 51 was removed by the developing treatment.

(5) Steps of Processing Release Layer and Blue Organic Compound Layer

Next, the release layer 30 not covered with the photosensitive resin layer 41 was removed and patterned with oxygen as a reactant gas under the conditions of a flow rate of 20 sccm, a pressure of 8 Pa, an output of 150 W, and a reaction time of 2 minutes. Thus, the patterned release layer 30 was formed in the region of the first sub-pixel 20 a (FIG. 2F). Further, the blue organic compound layer 22 a provided for the region except the region of the first sub-pixel 20 a was selectively removed by dry etching under the same conditions. Thus, the organic compound layer 22 a (blue organic compound layer) was formed in the region of the first sub-pixel 20 a (FIG. 2G).

(6) Steps of Forming and Processing Red Organic Compound Layer

Next, the red organic compound layer 22 b was formed by continuous film formation involving employing a vacuum deposition method. First, a hole transport layer was formed so as to have a thickness of 200 nm, and then an emission layer containing a red luminescence material was formed so as to have a thickness of 30 nm. Next, the condensed polycyclic hydrocarbon compound represented by the formula (1) was formed into a film so that a hole blocking layer was formed. At this time, the thickness of the hole blocking layer was set to 10 nm. Thus, the organic compound layer 22 b (red organic compound layer) was formed. Next, the phenanthroline derivative represented by the formula (2) was formed into a film by a vacuum deposition method so that the release layer 30 was formed. At this time, the thickness of the release layer 30 was set to 500 nm. Next, the positive photoresist used in the step (4) was formed into a film by a spin coating method so that the photosensitive resin layer 40 was formed (FIG. 2H). At this time, the thickness of the photosensitive resin layer was 1,000 nm. Next, the photosensitive resin layer 40 was processed by the same method as that in the step (4), and then the release layer 30 and the organic compound layer 22 b were processed by the same methods as those in the step (5). Thus, the organic compound layer 22 b (red organic compound layer) was formed in the region of the second sub-pixel 20 b (FIG. 2I).

(7) Steps of Forming and Processing Green Organic Compound Layer

Next, the green organic compound layer 22 c was formed by continuous film formation involving employing a vacuum deposition method. First, a hole transport layer was formed so as to have a thickness of 160 nm, and then an emission layer containing a green luminescence material was formed so as to have a thickness of 30 nm. Next, the condensed polycyclic hydrocarbon compound represented by the formula (1) was formed into a film so that a hole blocking layer was formed. At this time, the thickness of the hole blocking layer was set to 10 nm. Thus, the organic compound layer 22 c (green organic compound layer) was formed. Next, the phenanthroline derivative represented by the formula (2) was formed into a film by a vacuum deposition method so that the release layer 30 was formed. At this time, the thickness of the release layer 30 was set to 500 nm. Next, the positive photoresist used in the step (4) was formed into a film by a spin coating method so that the photosensitive resin layer 40 was formed (FIG. 2J). At this time, the thickness of the photosensitive resin layer was 1,000 nm. Next, the photosensitive resin layer 40 was processed by the same method as that in the step (4), and then the release layer 30 and the organic compound layer 22 b were processed by the same methods as those in the step (5). Thus, the organic compound layer 22 c (green organic compound layer) was formed in the region of the third sub-pixel 20 c (FIG. 2K).

(8) Steps of Removing Photosensitive Resin Layer and Release Layer

Next, the photosensitive resin layer 41 was removed by performing dry etching with oxygen as a reactant gas under the conditions of a flow rate of 20 sccm, a pressure of 8 Pa, and an output of 150 W (FIG. 2L). Next, the release layer 30 was removed with a mixed solvent obtained by mixing water and IPA so that an IPA concentration was 60 wt % (FIG. 2M). It should be noted that as the etching rate of the compound (phenanthroline derivative represented by the formula (2)) constituting the release layer 30 in this example was 0.9 nm/sec, the release layer 30 was removed through immersion in the mixed solvent for 600 seconds. Next, vacuum heating was performed at 80° C. so that the solvent remaining on the organic compound layer was removed. It should be noted that the etching rate of the compound represented by the formula (1) serving as the uppermost layer of the organic compound layer placed in each sub-pixel for the polar solvent used for removing the release layer is about 0.0045 nm/sec, which is sufficiently small as compared with the etching rate of the release layer 30.

(9) Step of Producing Second Electrode Etc.

Next, the compound represented by the formula (2) (compound A2) was formed into a film so that a charge transport layer (electron transport layer) was formed. At this time, the thickness of the charge transport layer was set to 20 nm. Next, the compound represented by the formula (2) and cesium carbonate (Cs₂CO₃) were co-deposited from the vapor so that an electron injection layer was formed. At this time, the thickness of the electron injection layer was set to 20 nm (FIG. 2N).

Next, an Ag film having a thickness of 16 nm was formed by sputtering so that the semitransparent second electrode was formed (FIG. 2O).

Next, a sealing glass (not shown) was bonded to the substrate under a nitrogen atmosphere so that a structure for preventing element deterioration was established. Thus, the organic EL display device was produced.

The organic EL display device 1 thus produced was evaluated by being compared with: an organic EL display device produced by employing photolithography in the same manner as in this example except that a PVP was used as a release layer; and an organic EL display device similarly produced except that the respective organic compound layers like a pattern were formed with a metal mask in a vacuum in-situ fashion. The device 1 was superior in current efficiency and drive durability life to the organic EL display device produced by using the PVP as a release layer, and obtained values for the parameters were comparable to those of the device in which the organic compound layers were formed in a vacuum in-situ fashion. This probably results from the achievement of the avoidance of a reduction in efficiency and the deterioration of the life attributable to the following fact. The deposited film formed by the vacuum deposition method was used as the release layer, and hence its removal was attained while the amount of the residue was reduced as compared with that in the case of the PVP. With regard to an increase in fineness, the employment of the photolithography method enabled the reduction of a pixel size to 9 μm square while the smallest pixel size obtained by a vapor deposition method involving using a fine metal mask was about 100 μm square.

Example 2

An organic EL display device was manufactured in the same manner as in Example 1 except the following. In Example 1, the following compound A7 (etching rate: 1.6 nm/sec) was used as a constituent material for the release layer 30. In addition, an immersion time in an IPA/water mixed solvent having the same mixing ratio as that in Example 1 upon removal of the release layer 30 was set to 330 seconds.

The resultant organic EL display device was evaluated by the same methods as those in Example 1. As a result, the device provided results comparable to those in Example 1 in terms of its current efficiency, drive life, and fineness.

Example 3

An organic EL display device was manufactured in the same manner as in Example 1 except the following. In Example 1, the following compound B1 (etching rate: 1.3 nm/sec) was used as a constituent material for the release layer 30. In addition, an immersion time in an IPA/water mixed solvent having the same mixing ratio as that in Example 1 upon removal of the release layer 30 was set to 400 seconds.

The resultant organic EL display device was evaluated by the same methods as those in Example 1. As a result, the device provided results comparable to those in Example 1 in terms of its current efficiency, drive life, and fineness.

Example 4

An organic EL display device was manufactured in the same manner as in Example 1 except the following. In Example 1, the following compound C1 (etching rate: 1.5 nm/sec) was used as a constituent material for the release layer 30. In addition, an immersion time in an IPA/water mixed solvent having the same mixing ratio as that in Example 1 upon removal of the release layer 30 was set to 340 seconds.

The resultant organic EL display device was evaluated by the same methods as those in Example 1. As a result, the device provided results comparable to those in Example 1 in terms of its current efficiency, drive life, and fineness.

Example 5

An organic EL display device was manufactured in the same manner as in Example 1 except the following. In Example 1, the following compound D6 (etching rate: 2.5 nm/sec) was used as a constituent material for the release layer 30. In addition, an immersion time in an IPA/water mixed solvent having the same mixing ratio as that in Example 1 upon removal of the release layer 30 was set to 220 seconds.

The resultant organic EL display device was evaluated by the same methods as those in Example 1. As a result, the device provided results comparable to those in Example 1 in terms of its current efficiency, drive life, and fineness.

Example 6

An organic EL display device was manufactured in the same manner as in Example 1 except the following. In Example 1, the following compound D8 (etching rate: 3.0 nm/sec) was used as a constituent material for the release layer 30. In addition, an immersion time in an IPA/water mixed solvent having the same mixing ratio as that in Example 1 upon removal of the release layer 30 was set to 180 seconds.

The resultant organic EL display device was evaluated by the same methods as those in Example 1. As a result, the device provided results comparable to those in Example 1 in terms of its current efficiency, drive life, and fineness.

Example 7

An organic EL display device was manufactured in the same manner as in Example 1 except the following. In Example 1, the step of forming the protective layer 60 was added between the step of forming the release layer 30 and the step of forming the photosensitive resin layer 40 to be performed upon processing of the organic compound layer (22 a, 22 b, or 22 c). In addition, the step of processing the protective layer 60 was added between the step of processing the photosensitive resin layer 40 and the step of processing the release layer 30. Further, the step of removing the protective layer 60 was added between the step of removing the photosensitive resin layer 41 and the step of removing the release layer 30. Hereinafter, a manufacturing process in this example is described with reference to FIGS. 5A to 5E with particular emphasis on the step of forming the protective layer, the step of processing the protective layer, and the step of removing the protective layer.

(1) Step of Forming Protective Layer Etc.

First, the layers up to the release layer 30 were formed on the supporting substrate 10 by the same methods as those in Example 1. Next, silicon nitride (SiN) was formed into a film by a CVD method on the release layer 30 so that the protective layer 60 was formed. At this time, the thickness of the protective layer 60 was set to 1,000 nm. Next, the photosensitive resin layer 40 was formed on the protective layer 60 by the same method as that in Example 1 (FIG. 5A).

(2) Step of Processing Protective Layer

Next, the photosensitive resin layer 40 was patterned. After that, the protective layer 60 not covered with the photosensitive resin layer 41 was removed with CF₄ as a reactant gas under the conditions of a flow rate of 30 sccm, an output of 150 W, a pressure of 10 Pa, and a treatment time of 7 minutes (FIG. 5B). That is, the protective layer 60 was processed in the step so that the protective layer 60 was provided in correspondence with the region of each sub-pixel.

(3) Step of Processing Organic Compound Layer

After that, the steps of processing the release layer 30 and the organic compound layer 22 a were performed by the same methods as those in Example 1 (FIG. 5C). Next, the steps (1) and (2) were performed in each of the second sub-pixel 20 b and the third sub-pixel 20 c so that the organic compound layers 22 b and 22 c to be provided for the second sub-pixel 20 b and the third sub-pixel 20 c, respectively were formed and processed (FIG. 5D).

(4) Step of Removing Protective Layer

Next, the photosensitive resin layer 41 was removed by the same method as that in Example 1. After that, the protective layer 60 was removed with CF₄ as a reactant gas under the conditions of a flow rate of 30 sccm, an output of 150 W, a pressure of 10 Pa, and a treatment time of 7 minutes. Next, the release layer 30 was removed by the same method as that in Example 1 (FIG. 5E). After that, the charge injection/transport layer 23 and the second electrode 24 were formed in the stated order by the same methods as those in Example 1. Thus, the organic EL display device was obtained.

The resultant organic EL display device was evaluated by the same methods as those in Example 1. As a result, the device provided results comparable to those in Example 1 in terms of its current efficiency, drive life, and fineness.

Example 8

In this example, an organic EL display device was manufactured in the same manner as in Example 7 except that the step of forming the protective layer, the step of processing the protective layer 60, and the step of removing the protective layer 60 in Example 7 were changed to methods to be described below. Hereinafter, description is given with reference to FIGS. 6A to 6F with particular emphasis on the step of forming the protective layer, the step of processing the protective layer, and the step of removing the protective layer.

(1) Step of Forming Protective Layer

First, the layers up to the release layer 30 were formed on the supporting substrate 10 by the same methods as those in Example 7. Next, an aqueous solution of a polyvinyl pyrrolidone (PVP, molecular weight: 360,000) as a water-soluble polymer material was prepared by mixing the PVP and water so that the weight concentration of the PVP was 5 wt %. Next, the prepared aqueous solution of the PVP was applied onto the release layer 30 by a spin coating method, and was then dried so that the first protective layer 61 was formed. At this time, the thickness of the first protective layer 61 was 500 nm. Next, silicon nitride (SiN) was formed into a film by a CVD method on the first protective layer 61 so that the second protective layer 62 was formed. At this time, the thickness of the second protective layer 62 was set to 1,000 nm. Next, the photosensitive resin layer 40 was formed on the protective layer 60 by the same method as that in Example 7 (FIG. 6A).

(2) Step of Processing Protective Layer

After the photosensitive resin layer 40 had been patterned so as to be left in the region of the first sub-pixel, the processing of the second protective layer 62 (selective removal of the second protective layer 62) was performed under conditions identical to those of the step (2) of Example 7 (FIG. 6B). Next, the first protective layer 61 not covered with the photosensitive resin layer 40 was removed with oxygen as a reactant gas under the conditions of a flow rate of 20 sccm, a pressure of 8 Pa, an output of 150 W, and 5 minutes. That is, the protective layer 60 formed of the first protective layer 61 and the second protective layer 62 was processed in the step so that the protective layer 60 was provided in correspondence with the region of each sub-pixel (FIG. 6C).

(3) Step of Processing Organic Compound Layer

The release layer 30 and the organic compound layer 22 a were processed with the photosensitive resin layer 40 and the protective layer 60 as masks in the same manner as in Example 1 (FIG. 6D). The steps (1) and (2) were performed in each of the second sub-pixel 20 b and the third sub-pixel 20 c so that the organic compound layers 22 b and 22 c to be provided for the second sub-pixel 20 b and the third sub-pixel 20 c, respectively were formed and processed (FIG. 6E).

(4) Step of Removing Protective Layer

The second protective layer 62 was removed in the same manner as in the step (4) of Example 7 after the removal of the photosensitive resin layer 40. Next, the first protective layer 61 was removed with oxygen as a reactant gas under the conditions of a flow rate of 20 sccm, a pressure of 8 Pa, an output of 150 W, and 5 minutes. Next, the release layer 30 was removed by the same method as that in Example 7 (FIG. 6F). After that, the charge injection/transport layer 23 and the second electrode 24 were formed in the stated order by the same methods as those in Example 7. Thus, the organic EL display device was obtained.

The resultant organic EL display device was evaluated by the same methods as those in Example 1. As a result, the device provided results comparable to those in Example 1 in terms of its current efficiency, drive life, and fineness.

As described above, the organic EL display device formed by the manufacturing method according to the present invention can find use in the display portions of various electronic equipments because the device is excellent in current efficiency, drive life, and fineness. Examples of the electronic equipments include digital cameras, portable equipments such as a personal digital assistant, personal computers, televisions, and various printers.

A digital camera as an example of the electronic equipments is described. FIG. 7 illustrates a block diagram of a digital camera system. A digital camera system 71 includes a photographing portion 72, an image signal processing circuit 73, a display device 74 according to the present invention, a memory 75, a CPU 76, and an operation portion 77. An image photographed by the photographing portion 72 or image information recorded in the memory 75 is subjected to signal processing in the image signal processing circuit 73 so that an image signal may be produced. The image signal can be displayed on the display device 74. A controller has the CPU 76 for controlling, for example, the photographing portion 72, the memory 75, and the image signal processing circuit 73 with an input from the operation portion 77, and performs photographing, recording, reproduction, and display suitable for situations.

While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

This application claims the benefit of Japanese Patent Application Nos. 2011-099393, filed Apr. 27, 2011, and 2012-068006, filed Mar. 23, 2012, which are hereby incorporated by reference herein in their entirety. 

What is claimed is:
 1. A method of manufacturing an organic electroluminescence display device comprising an organic electroluminescence element including a first electrode and a second electrode, and an organic compound layer arranged between the first electrode and the second electrode, the organic compound layer being patterned, the method comprising: an organic compound layer-forming step of forming the organic compound layer at least on the first electrode; a release layer-forming step of forming a first release layer and a second release layer on the organic compound layer; a release layer-processing step of processing the first release layer and the second release layer; an organic compound layer-processing step of removing the organic compound layer in a region not covered with the first release layer and the second release layer processed in the release layer-processing step; and a release layer-removing step of removing the first release layer and the second release layer with a polar solvent, wherein: the organic compound layer-forming step comprises a step of forming an uppermost layer of the organic compound layer from a condensed polycyclic hydrocarbon compound except a compound having an m-terphenyl group; and the release layer-forming step comprises: a step of forming the first release layer soluble in the polar solvent from a low-molecular weight material by a vacuum deposition method, the first release layer being in contact with the organic compound layer; and a step of forming, on the first release layer, the second release layer soluble in the polar solvent from a polymer material by a spin coating method.
 2. The method according to claim 1, wherein the first release layer comprises a compound soluble in the polar solvent, and the compound comprises one of a compound having a polar site and a compound having an m-terphenyl group.
 3. The method according to claim 1, wherein the polar solvent used in the release layer-removing step contains water.
 4. The method according to claim 1, wherein: $n = {\frac{\left\lbrack {{Etching}\mspace{14mu}{rate}\mspace{14mu}{of}\mspace{14mu}{the}\mspace{14mu}{first}\mspace{14mu}{release}\mspace{14mu}{layer}} \right\rbrack}{\left\lbrack {{Etching}\mspace{14mu}{rate}\mspace{14mu}{of}\mspace{14mu}{uppermost}\mspace{14mu}{layer}\mspace{14mu}{of}\mspace{14mu}{organic}\mspace{14mu}{compound}\mspace{14mu}{layer}} \right\rbrack} > 10}$ where n is a ratio of etching rates is established in the release layer-removing step.
 5. The method according to claim 1, further comprising a step of forming a layer containing an alkali metal component on the organic compound layer after the release layer-removing step.
 6. An electronic equipment, comprising: a display device; a memory; a CPU; and an operation portion, wherein the display device comprises an organic electroluminescence display device manufactured by the method according to claim
 1. 